Empty industrial plant hall with overhead cranes, ready for a phased equipment transition.
Brownfield Modernization

Modernize While the Plant Stays Online

CPLANE helps plants and the system integrators who serve them move off a proprietary PLC or DCS in phases. Production stays online. Cybersecurity is designed in.

Quick estimate

Downtime cost avoided with a phased cutover

$250,000
21 days
2 days

$4.8M

19 production days kept

How CPLANE does it

Compares a single big-bang cutover with migrating one isolatable unit at a time.

Revenue pulled forward

50 MW
$150
6 weeks

$10.4M

$1.7M per week of delay

How CPLANE does it

Every week of commissioning delay is a week of unbilled capacity.

Annualized OT downtime exposure

$250,000
7 days
10%

$175,000

Single incident: $1.8M

How CPLANE does it

Illustrative only, not a risk assessment.

Annual value from optimization

$200.0M
1.5%
$20.0M
5%

$4.0M

$3.0M yield, $1.0M energy

How CPLANE does it

Adds a yield or throughput gain on production value to a reduction in annual energy spend.

Set up a Strategy Call

A Replacement Does Not Have to Stop the Plant

A proprietary PLC or DCS ties the outage, the spares, and the next upgrade to one vendor. A full rip-and-replace is often the only path that vendor will quote.

A phased cutover keeps production running. Field wiring can stay. Compute and the control application move in steps the plant can schedule.

Talk with an Expert

How We Start

Phased modernization that keeps the plant online.

Step 1

Map the Installed System

What is running, which units can move first, and where a full outage is not an option.

Step 2

Prove One Unit

Live control starts on one isolatable unit. The rest stays on the installed stack until that unit proves itself.

Step 3

Keep the Integrator

CPLANE does not go around the SI who already knows the plant. Engineering, the integrator, and operations stay in the loop.

Step 4

Evaluate on the Fusion 500

Validate the platform on the Fusion 500 before a wider rollout. Same stack as production.

Built for Brownfield Modernization

Installed plants. One open control architecture.

Installed PLC and DCS systems

Process units already running on a proprietary PLC or DCS. The plant stays in production while one unit moves at a time.

  • Units that cannot take a full outage
  • Skids and areas that can move one at a time
  • Field wiring and I/O you can keep
One pane of glass. One security perimeter.
Empty industrial plant hall with overhead cranes, ready for a phased equipment transition.

Lock-in sets the outage

When one OEM controls the spare-parts price, the upgrade window, and the replacement quote, the plant has one path. That dependency compounds over a long asset life.

  • A full replacement is often not in the budget
  • The vendor sets the cutover window
  • Spares and the next upgrade stay on one price list
Modernize compute. Keep the field wiring.
Proprietary control hardware.

Modernize while production stays online

Units move onto O-PAS in phases. One capital vote does not have to replace the whole plant.

  • Start on one isolatable unit
  • Keep field wiring when rewiring costs more than a short outage
  • Expand after that unit proves itself
Your SI stays in the loop.
Two engineers in safety gear coordinating on an industrial site.

Open, software-defined control

Harder to attack, easier to patch, cheaper to sustain, and free of single-vendor dependency at every layer. Software failover in under one control cycle. No extra standby chassis.

  • Patch and swap a node on the plant's schedule
  • Patch and swap a node without a maintenance window
  • Multiple vendors can supply standards-based components
Not a lock-in swap.
Process plant piping and equipment.

Designed in, not bolted on

The control layer is built to IEC 62443-4-2 SL2. A February 2026 U.S. Army red team found no vulnerabilities that allowed unauthorized access to control.

  • Zone the plant. Access through a gateway.
  • Not a substitute for red-teaming or taking controllers off the internet today.
  • A password change on a controller is an operations event.
Residual risk is never zero.
Control engineer working at an industrial workstation.

In production, and relevant here

Open control on this stack is in production at an ExxonMobil chemical terminal, a continuous process with the same constraint a brownfield unit has: the plant stays online. Fusion 500 is the evaluation unit before a wider rollout.

  • Continuous process, in production
  • ExxonMobil chemical terminal, in production
  • Evaluation on the Fusion 500 before a wider rollout
High availability is the argument that still keeps plants on a closed controller. That account is in Resources.
Fusion 500 evaluation unit.

CPLANE is delivered by a global network of certified systems integrators.

Find a Partner

Modernize in Phases

A phased path that keeps field wiring and stays inside the budget you have.

The plant stays online.